Dental device material preparation

ABSTRACT

The present invention is a dental device comprising natural and sustainable materials. These materials are derived from the nut of the tangua palm tree that may be fashioned into devices for human and animals when replacing one or more teeth of the subject.

I claim priority to my provisional application, Ser. No. 6/141,3061,filed on Nov. 12, 2010.

SUMMARY OF THE INVENTION

The present invention applies to typical dental devices or applianceshaving chewing surfaces comprising naturally derived materials obtainedfrom sustainable resources. The natural material has physicalcharacteristics providing durability, texture, color and shading thatmatch natural teeth necessary for utilitarian and cosmetically pleasingdental devices. The natural materials are sufficiently workable whenusing normal manufacturing techniques and equipment routinely appliedfor making currently available dental devices comprising non-natural orsustainable materials such as metal and ceramics.

BACKGROUND OF THE INVENTION

Animals, particularly humans have natural teeth to assist in masticationof food and are essential for sustaining good health. Teeth, however,comprise living tissue that may be corruptible by neglect, abuse and, ordisease. In extreme cases decayed or damaged teeth are not reparablewith typically available prophylaxis and must be extracted for the wellbeing of the patient. Notwithstanding removal, in the opinion of dentalprofessionals, it is important that extracted teeth be replaced byprosthesis equipped with chewing surfaces. Replacements for teeth andthe method for making such replacements are well known to those skilledin the art and include devices selected from the group consisting ofbridges, full dentures, partial dentures, crowns, caps and combinationsthereof.

The aforementioned dental devices are currently made from a number ofmaterials that provide sufficient durability to sustain the rigors ofchewing as well as provide good cosmetic aesthetics to match theremaining natural teeth in terms of physical factors including, but notnecessarily limited to shape, size, texture and color. Currently thematerials used to make such devices include non-sustainable preciousmetals such as gold, ceramics, porcelain, plastics or composites ofthese materials. Standard dental devices are typically made of the abovematerials with a uniform high degree of hardness throughout thematerial. Unlike natural teeth which consist of multiple layers oforganic and mineral material in an ascending degree of hardness, fromroot to dentin to enamel, which has both formal and functional qualitiesand characteristics. Those qualities and characteristics are perfectlyadapted to provide a kind of cushion or shock absorbing effect whichprotects the surrounding maxillofacial structure from stress induceddamage. Such damage can include serious bone, muscular, and nervedamage, which is more likely to occur when superfluously hard and rigiddental prosthetics, replace natural teeth which have a shock absorbingquality.

The present invention provides a natural, agriculturally derivedsolution that has substantially the same variable component hardness,and cushioning effect, as natural teeth.

Most dentists and dental patients have expressed high interest inprosthetic dental devices comprising natural, sustainable or “green”materials. Up to now, however no suitable natural and sustainablematerials has been found to be a satisfactory in terms of the physicalattributes previously mentioned. Therefore, there remains an unmet needfor dental devices comprising a natural, sustainable material.

BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS

The drawings consist of seven figures relating to the seed of the TaguaNut Palm and the an exemplary series of steps involved in processing theendosperm portion of it to produce dental devices that are the subjectof the present invention. They consist of seven figures depicting theTagua Nut, its endosperm, typical shapes of processed material, thechemical formula of hydroxyapatite, sample computerized milling devices,and examples of possible dental devices. The figures are numbered onethrough seven (1-7).

DETAILED DESCRIPTION OF THE INVENTION

A. The Dental Device Material

In a embodiment of the invention, the dental devices comprise dehydratedand hardened endosperm of the nut of the Tagua palm, a species of thegenus Phytelephas [FIG. 1]. Phytelephas is a genus containing sixspecies of palms (family Arecaceae), occurring from southern Panamaalong the Andes to Ecuador, Bolivia and Peru. They are medium-sized totall palms reaching 20 meters tall, with pinnate leaves. They arecommonly known as ivory palms, ivory-nut palms or Tagua palms; theirscientific name means “plant elephant”. This and the first two of thecommon names refer to the very hard white endosperm of their seeds(Tagua nuts), which resembles elephant ivory. In its original state, the“nut” is covered with pericarp . The nut is covered with a brown, flakyskin and shaped like a small avocado, roughly 4-8 cm in diameter. Sincethe nut has a protective husk or shell, once the nuts are harvestedthere are no extreme inspection, sorting and handling that must be takento sort the nuts before processing. This material is harvested by theusual manual or machine harvesting methods generally known in the art.

The dehydrated Tagua nut material's texture, color and shading vary overthe range normally associated with natural teeth. To that end, thedesired shading and color of the material is selected individually forthe patient prior to manufacturing the device. Furthermore, the color ofthe material can be modified by routine method known in the art forbleaching material or foods such as wheat flour. Additionally thetexture of the material may be manipulated to create a consistentsurface of the device that matches the natural teeth to avoidpreoccupation by the patient's tongue.

B. Processing the Dental Device Material

Processing the dental device material derived from the Tagua nutsincludes the steps of shelling, and curing the nuts by dehydration ordesiccation. Dehydration or desiccation may be achieved wherein the nutsare dried at ambient conditions or accelerated using industrialequipment to rapidly drive off water to a desired level of dryness. Suchequipment is well known in the foods industry. The point whereupon thenuts are sufficiently dehydrated for manufacturing dental devices is atthe point of comparable hardness of the natural dentin part of a tooth.Standard testing equipment to makes such measurements includes anInstron® Device. This device may be set to measure compressive strengthin Pascals that is defined as the value of uniaxial compressive stressnecessary to achieve complete failure of the material. Other methods oftesting hardness include the Mohs Hardness method. The Mohs Scale ofmineral hardness characterizes the scratch resistance of variousminerals through the ability of a harder material to scratch a softermaterial. The Mohs Hardness of dehydrated Tagua is roughly theequivalent to the Mohs Hardness of natural tooth dentin, ranging between2.5 and 4 on the Mohs Hardness scale. Upon reaching compressive strengthcomparable to the primary dentin subsurface part of a natural tooth, thenut meat [FIG. 2] is processed and shaped into blocks, or other shapes[FIG. 3], that are of certain standard dimensions that are equivalent tothose of the standard artificial material currently used in the computeraided design or CAD and manufacturing of dental prostheses.

Among the systems known to those skilled in the art of dental devicemanufacturing is the Chairside Economical Restoration of EstheticCeramics™ Series including the CEREC™ AC dental milling device. Suchmilling devices carve blocks of ceramic, composite, or other suitablyhard material that are made in such dimensions as to fit in the millingcompartment of the machine. The milling device fashions a product ofcertain size and quality based upon a computer generated 3 dimensionalrendering of a particular patient's data. The dehydrated Tagua nutendosperm is preliminarily shaped according to the requirements for usein the CEREC device, or any other brand of milling device, in such a waythat a uniform and consistently solid piece in the desired shape anddimensions is produced without any of the naturally occurring gaps orcrevices found in the nut. The pieces of Tagua may at this stage ofproduction be treated in one of several ways with the mineralhydroxylapatite [FIG. 3] which is a naturally occurring mineral which isa primary element in human teeth and bone. One method of treating thedehydrated Tagua endosperm is to bath the Tagua within a solution ofhydroxylapatite under such conditions that achieves a suitable coatingand desired hardening of the surface. Hydroxylapatite, also calledhydroxyapatite (HA), is a naturally occurring mineral form of calciumapatite with the formula Ca₅(PO₄)₃(OH), but is usually writtenCa₁₀(PO₄)₆(OH)₂ to denote that the crystal unit cell comprises twoentities. Hydroxylapatite is the hydroxyl end member of the complexapatite group. The OH⁻ ion can be replaced by fluoride, chloride orcarbonate, producing fluorapatite or chlorapatite. It crystallizes inthe hexagonal crystal system. Pure hydroxylapatite powder is white.Naturally occurring apatites can, however, also have brown, yellow, orgreen colorations, comparable to the discolorations of dental fluorosis.Alternative coating methods can be used that involve adhesion oradmixture of the Tagua endosperm with the hydroxylapatite. A thermal orplasma surface treatment method may be used for example. Moreover thetreatment may also be made, or repeated, after the final dentalprosthetic has been carved. Such treatment is used when additionalhardness or other qualities that result from the treatment are desired.

Pulverization of dehydrated Tagua provides for later reconstitution ofthe material in various admixtures with hydroxyapatite such that desiredqualities of size, shape, and hardness may be achieved [FIG. 4]. Variousstandard chemical treatments can be applied to adjust qualities of size,color, and hardness.

Before placing the dehydrated Tagua nut endosperm into the CEREC orother milling device, a standard abutment or stem may be attached to thepiece so that it can be held and manipulated by the device during themilling step. [FIG. 5]. Then the appropriately sized and shaped piecethat is suitable to produce the desired prosthetic for given patient iscarved in accordance with the computer assisted design data related tothe patient using the milling device [FIG. 6], so as to be capable ofattachment to a dental implant.

The resulting prosthetic [FIG. 7] is then attachable to a patient'sstandard implant which may be of any type. Alternatively, the prostheticcan be fitted to cap a broken tooth by mounting upon a suitably preparedfractional part of an original remaining tooth or teeth. The resultingprosthesis may be of any type, without limitation to, a cap, crown,bridge, partial, or complete denture set. The prosthetic need not attachpermanently to implants, as when comprising a removable denture set orbridge for example.

Because the dehydrated endosperm of the Tagua nut, while sufficientlyhard, is not superfluously hard in comparison to natural teeth as arethe typical ceramic and composite materials ordinarily used by dentalmilling devices, the carving bits need changing less frequently. What'smore less expensive carving bits may be used in place of the diamondbits otherwise needed.

It is apparent that the sequence of steps involved here may be alteredand that other vegetable material of the same genus and species may besubstituted for the Tagua nut endosperm without departing from thespirit and scope of the invention. The prostheses contemplated can alsobe hand carved, using standard power or hand carving tools, both duringthe fabrication stage and for the purpose of making fitting adjustments.

A sustainable green business is attained by the practice of the methodshere that provides a more biocompatible dental prosthesis without anyadverse impact on patient health in contrast to the potentially toxicelements, byproducts, and waste related to the manufacturing of othercurrently used ceramic, composite, artificial products.

The above invention is not necessarily limited in scope and includeswhat those skilled in the art and include discernible variations ormodification obvious to one skilled in the art.

1. A dental device having chewing surfaces comprising naturally derivedmaterials having physical characteristics to provide comparable hardnessand appearance qualities as natural teeth.
 2. A dental device of claim 1wherein the naturally derived material of comprises the dehydratedendosperm of Tagua palm nut.
 3. The material of claim 2 wherein thehardness of the material is from about 2.5 to about 4 on the MohsHardness Scale.
 4. The material of claim 2 wherein the material istreated with a solution which results in the formation ofhydroxylapatite upon the material under such conditions that achieves asuitable coating and desired hardening of the surface.
 5. A dentaldevice comprising the material of claim 3 wherein the device is selectedfrom the group consisting of bridges, full dentures, partial dentures,crowns, caps and combinations thereof.
 6. A dental device of claim 5wherein the device is in the form of a dental crown.
 7. The crown ofclaim 6 wherein the crown material matches the color and shading of thenatural teeth of the patient.
 8. A method of making the dental devicesof claim 5 comprising the steps of: a. harvesting Tagua nuts; b. removethe shells of the Tagua Nuts; c. dehydrating the nuts; and d. millingthe nuts to the shape of the subject teeth.
 9. A method for fitting adental device for a patient comprising the steps of: a. measuring thepatient's teeth to be extracted for color, texture, shape and size; b.selecting the material of claim 2 to match the patient's tooth for colorand texture; c. having the teeth milled to the patient's shape and size;d. fitting the milled teeth to the patient's mouth.
 10. A method ofmaking a dental prosthesis a. preparing dehydrated Tagua nut endospermmaterial b. reshaping the dehydrated Tagua in the shape of a dentalprosthesis using a computer assisted machine c. such that the prosthesisis capable of being attached to a dental implant mount
 11. The method ofclaim Number 1 wherein hydroxylapatite is added to the Tagua nutmaterial to provide a desired quality.
 12. A Dental Cap or Crown a. madeof carved or milled Tagua nut material that is sealed by a layer ofnaturally occurring mineral to provide a desired quality. b. using athree dimensional digital image of a tooth to be replaced c. using aprocessor to guide the step of carving or milling the Tagua nut materialinto the form of a tooth capable of replacing the original to bereplaced tooth.
 13. Dentures made of dehydrated Tagua nut material a.carved or milled by means of a processor b. controlling a milling orcarving machine that mills the Tagua material into a prosthetic suitablefor dental use
 14. The Prosthesis of claim Number 3 wherein the Taguanut material is combined with an additional material to provide adesired quality.
 15. The Dentures of claim 3 wherein the additionalmaterial is a mineral.
 16. A business method that uses sustainablepractices and which reduces the amount of energy needed to manufacturedental prostheses while providing agricultural jobs in impoverishedeconomies by replacing ceramic and other artificial materials used tomake dental prostheses, that are produced by energy intensive means andwhich generate a relatively high carbon output and waste products, withTagua nut endosperm that is dehydrated and reshaped so that can replacethe materials currently used in existing milling systems.
 17. Abiocompatible composite material for fabricating dental prothesesDehydrated Tagua nut endosperm treated with hydroxylapatite in shapesand sizes suitable for use in standard dental milling devices.